Advertisement
Quick Links
Model Include:
This instructional manual is only intended for use by a qualified service professional or authorized Noritz
Service Representative. Any unauthorized use of this manual may result in voiding the warranty.
Please contact Noritz Technical Support (866‐766‐7489) for additional support.
SKJ70F6‐1
Rev. 02/13
NRC661 Series Heat Exchanger
Replacement
NRC661‐DV, NRC661‐OD
Noritz America Corporation
11160 Grace Avenue, Fountain Valley, CA 92708
Phone 866‐766‐7489 Fax 714‐241‐1196
Page 1
Advertisement
Related Manuals for Noritz NRC661 Series
Summary of Contents for Noritz NRC661 Series
- Page 1 NRC661 Series Heat Exchanger Replacement Model Include: NRC661‐DV, NRC661‐OD This instructional manual is only intended for use by a qualified service professional or authorized Noritz Service Representative. Any unauthorized use of this manual may result in voiding the warranty. Please contact Noritz Technical Support (866‐766‐7489) for additional support. Noritz America Corporation 11160 Grace Avenue, Fountain Valley, CA 92708 Phone 866‐766‐7489 Fax 714‐241‐1196 SKJ70F6‐1 Rev. 02/13 Page 1...
- Page 2 NRC661 Series Heat Exchanger Replacement Procedure Procedure Diagram Remove front cover (1) Disconnect electrical power to unit (2) Turn off gas and water (3) Remove 4 screws (4) Remove drain valves (2) and drain unit completely (5) Remove cover ‐ circuit board Cover ‐ Circuit Board Disconnect the connectors from circuit board and remove the OD model has only a screw ground wire, circuit board of the upperside (1) Disconnect the connectors from circuit board (2) Remove the ground wire DV model; 3 ground wires OD model; 2 ground wires (3) Remove the circuit board; there are 2 screws, one on the right‐side and middle‐upper of the circuit board. Let the circuit board hang outside of the unit Unplug all wires that attach to the wiring harness and the body of the water heater (1) Flame rod and ignition plug (2) Loosen wire anchor from right side of case and unplug freeze prevention heater, thermal fuse (2) (3) Unplug all wires that attach to the wiring harness except water servo ‐ main (4) *DV model only Unplug freeze prevention heater, thermistor...
- Page 3 NRC661 Series Heat Exchanger Replacement Procedure Procedure Diagram Remove manifold plate (1) Remove the 3 big silver screws on the manifold plate that attach the manifold to the burner (2) Remove the 2 smaller silver screws from the manifold plate that attach the manifold to the gas valve (3) Remove manifold plate and unplug the connector from gas solenoid valves (3) Disconnect water pipes from water flow sensor and water servo ‐ main (1) Remove "C" Clamp (3) (2) Remove the water flow sensor (3) Make sure to feed the wires from water servo ‐ main around the outlet water pipe as shown in bottom diagram Wiring harness (2,3) Water Flow Sensor Page 3...
- Page 4 NRC661 Series Heat Exchanger Replacement Procedure Procedure Diagram Remove flue from top of unit *DV model only (1) Disconnect the venting from the unit (2) Remove the 4 screws and pull the flue off of the unit and set aside Remove the drain hose from Stainless Steel Heat Exchanger(SS HE) (1) Remove the 1 spring clamp (2) Remove the drain hose from SS HE and pull the hose out as shown in the right diagram (2) Remove cover and route wires ‐ water level electrode (1) Remove cover ‐ water level electrode from condensate container (2) Make sure to feed the wires from water level electrode wiring harness outside the case as shown in diagram (2) (3) Make sure to feed the wires from high limit switch and thermistor ‐ heat exchanger wiring harness as shown in diagram (3) Page 4...
- Page 5 NRC661 Series Heat Exchanger Replacement Procedure Procedure Diagram Remove heat exchanger from case (1) Remove the 2 set screws on the bottom of the burner (2) Remove the upper left and right set screws near the top of the case (OD Models the screws will be at the top center of the case) (support bottom of assembly) (3) SS HE, Copper Heat Exchanger(CU HE), Burner, and Fan will come out in one section. Remove from unit. (2) DV model (2) OD model Separate the SS HE from CU HE (1) Remove the 2 screws on the bracket between the SS HE and CU HE (2) Remove the 3 screws that located on the back side of the SS HE (3) Remove "C" clamp (4) Separate the SS HE from the CU HE Page 5...
- Page 6 NRC661 Series Heat Exchanger Replacement Procedure Procedure Diagram Replacing SS HE Note: If you are not replacing the SS HE then you can skip this step and set SS HE aside. (1) Remove old gasket between SS HE and CU HE Exhaust Box and replace with new one (2) *OD model only Remove the gasket on the front of the SS HE and place on new SS HE (2) OD model only Replacing the CU HE (1) Remove 10 screws holding burner to CU HE (2) Separate burner from CU HE Remove heat exchanger components from old heat exchanger and put on new heat exchanger (1) Front side: Freeze prevention heater (2) Left side: High limit switch and thermistor ‐ heat exchanger *Replace new O Ring fot the thermistor ‐ heat exchanger For the high limit switch and thermistor ‐ heat exchanger. Make sure to route the wire as shown in the diagram. Page 6...
- Page 7 NRC661 Series Heat Exchanger Replacement Procedure Procedure Diagram (3) Thermal fuse and fasteners from 4 sides of heat Right side exchanger, See the 4 views of the heat exchanger to make sure the thermal fuse is routed correctly Install the thermal fuse(White) inside of the stopper The end of insulation tube(Black) and the front of heat exchanger are lined up Stopper Back side Keep the thermal fuse straight Left side ‐ 1 Make sure to route the thermal fuse as shown in the diagram to Left side ‐ 2 the right (Left side ‐ 1 & 2) Front side Page 7...
- Page 8 NRC661 Series Heat Exchanger Replacement Procedure Procedure Diagram (4) *DV model only Replace freeze prevention heater with one that was Left side of HE shipped in the heat exchanger kit. Wrap freeze prevention heater around inlet pipe to CU HE. Replace gaskets (1) Remove old burner gasket and replace with new one (2) Remove old gasket between SS HE and CU HE Exhaust Box and replace with new one Place new O Rings on new CU HE (1) Inlet to CU HE (2) Exit to CU HE Page 8...
- Page 9 NRC661 Series Heat Exchanger Replacement Procedure Procedure Diagram Reattach burner, CU HE, and SS HE (1) Attach inlet pipe to CU HE with the “C” Clamp. Make sure to insert pipe in all the way before attaching “C” Clamp. (2) Attach the 3 screws that located on the back side of the SS HE to hold the SS HE to the CU HE (3) Attach the 2 screws on the bracket between the SS HE and CU HE (4) Attach the 10 screws around perimeter of burner and heat exchanger Replace assembly back inside case (1) Secure the 2 set screws on the bottom of the burner (2) Secure the upper left and right set screws near the top of the case (OD Models the screws will be at the top center of the case) (2) DV model (2) OD model Page 9...
- Page 10 NRC661 Series Heat Exchanger Replacement Procedure Procedure Diagram Replace flue from top of unit *DV model only (1) Attach the flue to the unit and secure the 4 screws (2) Reconnect the venting to the unit Reconnect water connections (1) Maintain high limit switch, thermistor ‐ heat exchanger and water level electrode wiring harness as shown in diagram (1) (2) *DV model only Maintain freeze prevention heater and thermistor ‐ exhaust wiring harness as shown in diagram (2) (3) Maintain wiring harness as shown in diagram (3) (4) Insert pipe from CU HE to water servo ‐ main and attach "C" clamp (5) Insert water flow sensor to inlet water connection and attach "C" clamp. And then insert water inlet pipe to water flow sensor and attach "C" clamp. Replace the drain hose to SS HE (1) Replace the drain hose to SS HE and reattach the 1 spring clamp as right diagram Page 10...
- Page 11 NRC661 Series Heat Exchanger Replacement Procedure Procedure Diagram Replace manifold plate (1) Plug the connector to gas solenoid valves (3) as right diagram (2) Confirm that there is o‐ring before replace manifold plate (3) Replace the 2 smaller silver screws from the manifold O & BL GY & BL plate that attach the manifold to the gas valve BK & BL wire wire (4) Replace the 3 big silver screws on the manifold plate wire that attach the manifold to the burner (5) Hand tighten all 5 screws equally Check for water leaks (1) Replace drain valves (2) (2) Turn on cold water shut off valve slowly (check for leaks around “C” clamps) (3) If you get leaks shut off water and re‐secure “C” Clamps Page 11...
- Page 12 NRC661 Series Heat Exchanger Replacement Procedure Procedure Diagram Plug all wires that attach to the wiring harness and the body Thermistor ‐ Air of the water heater (1) Plug all wires that attach to the wiring harness (2) Tie wires by cable tie as right diagram (3) Tie wires by cable tie as right diagram Thermistor ‐ Cold Water Thermistor ‐ Hot Water Water Flow Sensor (4) Put the all wires in the position as shown in diagram Cable Tie *OD model only Put the yellow connector in the position as shown in diagram (4) OD model only (5) Secure the ground wire Cable Tie (4) OD model only Yellow Connector Page 12...
- Page 13 NRC661 Series Heat Exchanger Replacement Procedure Procedure Diagram (6) Replace the circuit board; secure 2 screws, one on the OD model has only a screw right‐side and middle‐upper of the circuit board. of the upperside Secure the ground wire. DV model; 2 ground wires OD model; 1 ground wires (7) Reconnect the connectors to circuit board (8) Plug freeze prevention heater, thermal fuse (2) and tie it by wire anchor to right side of case as right diagram (9) Plug flame rod and ignition plug (10) *DV model only Plug freeze prevention heater, thermistor ‐ exhaust. Secure the wire by clamps (2) as shown in diagram (10) Take out all wires from the left side of the line (10) Wire clamp Page 13...
- Page 14 NRC661 Series Heat Exchanger Replacement Procedure Procedure Diagram (11) Replace cover ‐ water level electrode to condensate (11) container (12) *DV model only Reinstall power supply cord as right diagram (13) Put all wires as right diagram (12) (13) Page 14...
- Page 15 NRC661 Series Heat Exchanger Replacement Procedure Procedure Diagram (14) Replace cover ‐ circuit board Cover ‐ Circuit Board Check for gas leaks and doing trial operation (1) Turn on gas (2) Turn on the unit. Check for leaks around manifold plate and joining areas. For example ‐ Between Burer and CU HE (3) If you get leaks shut off gas, water and re‐secure leaking points Replace front cover (1) Secure front cover with 4 screws Page 15...